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Optimization of Processing Water Treatment and
Its Reuse in Bauxite Flotation
LIQING SUN1,2, ZILONG MA2,*, LULU LIAN1,2, QING WANG1,2, LIJUAN SUN1,2 and JIE LIU1,2
1School
of Chemical Engineering and Technology, China University of Mining and Technology, Xuzhou 221116, Jiangsu, China
2National Engineering Research Center of Coal Preparation and Purification, Xuzhou 221116, Jiangsu, China
ABSTRACT: The optimum condition for the sedimentation process of concentrate pulp
and tailing pulp in bauxite flotation was determined based on the supernatant turbidity
study. The flotation tests were conducted to study the effect of recycled water turbidity
and recycling time on the concentrate grade and recovery. The results demonstrate
that recycled water with turbidity over 95 Nephelometric Turbidity Units (NTU) cannot
achieve the ideal concentrate compared to fresh water. In addition, recycled water that
was reused twice in bauxite flotation demonstrated reduced selectivity. This is mainly
caused by the accumulation of chlorine ions, which may enhance the entrainment of
clays in the concentrate.
INTRODUCTION
T
diasporic bauxite mineral resources have a
wide distribution in China, which always have a
low Al2O3 to SiO2 (A/S) mass ratio ranging from 4 to
6 [1]. Flotation has been identified to be an effective
method for separating fine and valuable minerals from
other composites [2–4]. For the diasporic bauxite ore,
the flotation method can improve the A/S ratio to meet
the requirements for Bayer Technology. The volume of
water required for processing the diasporic bauxite is
at least 3 m3 per ton. In order to preserve water and
reduce water discharge, the processing water must be
recycled in the flotation.
Solid-liquid separation after flotation has attracted
extensive attention worldwide [5–8]. Sedimentation is
the primary technique in the dewatering process [9].
In most cases, efficient separation of the solid and process liquid is quite challenging and complicated. As the
sizes of the solid particles are often less than 10 μm, it
is difficult for the fine particles to settle down or settle
quickly. In addition, the clay minerals such as kaolinite, illite, and pyrophyllite are often negatively charged
and mutually exclusive, making the slurry stable [10–
15]. To overcome these challenges, coagulants or floche
*Author to whom correspondence should be addressed.
E-mail: [email protected]
culates are extensively used to promote sedimentation
[6,16,17]. Polyacrylamide (PAM) is commonly used
as a flocculant in water treatment, but is less efficient
when used alone, due to the weak interaction between
PAM and the particles or the repulsive force between
the chain of PAM and the particles [18–20]. Therefore,
coagulates such as aluminum sulfate and poly-aluminum chloride (PAC) are added before PAM to neutralize the charge on the particle surface [21,22].
So far, various reports have studied the process
water recycling in flotation, and the results show that
the flotation results were closely related to the water
quality [5,23–25]. The process water often contains
numerous ions, agents, and particle residue, which is
considerably different from fresh water. The ions may
originate from mineral dissolution and reagent addition [26–28]. The mineral dissolution also contributes
a small amount of substances to the flotation water,
due to the low solubility from certain materials [29].
However, these constituents can be enhanced through
processing water recycling, thus affecting the flotation
performance. For example, in a complex sulphide flotation plant, the accumulation of copper ions can activate the sphalerite flotation [30]. Similar to mineral
dissolution, the reagent also contribute a small portion
of substances, and these substances can also accumulate and affect the flotation performance [31].
In this study, we aim to optimize the processing
water treatment and investigate its reuse capability in
Journal of Residuals Science & Technology, Vol. 14, No. 2—April 2017
1544-8053/17/02 163-08
© 2017 DEStech Publications, Inc.
doi:10.12783/issn.1544-8053/14/2/19
163
164
L. SUN, Z. MA, L. LIAN, Q. WANG, L. SUN and J. LIU
bauxite flotation. The influence of the pH value and
the combination reagent of coagulant-flocculant on
sedimentation efficiency were investigated to define
the optimum experimental conditions for coagulation
and flocculation. The flotation tests were carried out
to study the relationship between water turbidity and
flotation performance. Moreover, we also studied the
processing water that was obtained by sedimentation
of pulp under the optimum conditions and reused twice
in flotation.
MATERIALS AND METHODS
Materials
The bauxite ore used in this study were obtained
from Daoer in Shanxi Province. The lumps of the bauxite were first crushed by a jaw crusher, then screened
and grounded to ensure that 85% of the minerals pass
the 200-mesh sieve. The chemical analysis is shown in
Figure 1, which indicates that the bauxite sample contains 60% aluminum oxide and 15% silicon dioxide,
with an A/S ratio of 4.
The concentrate pulp and tailing pulp used for sedimentation study were also obtained in positive floatation from Shanxi Daoer investment co., LTD. The sample was mixed evenly through riffle before the basic
characteristic analysis. The chemical analysis (Figure
1) indicates that the minerals in the concentrate and
tailing pulp are 65%, 50% aluminum oxide and 11%,
23% silicon dioxide, with the A/S ratio of 5.9 and 2.1,
respectively. The particle sizes of bauxite ore, concentrate pulp, and tailing pulp were analyzed by MasterSizer 2000 (Malvern Instruments). As shown in Figure 2, the results indicate that bauxite ore, concentrate
pulp, and tailing pulp have a median diameter (d50) of
8 μm, 6 μm, and 13 μm, respectively.
The PAM and PAC used as flocculant and coagulant
were purchased from Zhengzhou in Henan province.
Sodium oleate, synthesized by oleate and NaOH in the
laboratory, was used as collector in the flotation tests.
Na2CO3 (AR) and HCl (AR) were used in the tests as
pH modifiers. Sodium hexametaphosphate (AR) was
used as dispersant. Distilled water was used in all of
the experiments except the ones that require recycled
water.
Figure 1. The chemical components of: (a) bauxite ore, (b) concentrate pulp and (c) tailing pulp.
Optimization of Processing Water Treatment and Its Reuse in Bauxite Flotation
165
Ion-chromatographic Measurements
The ion content in the samples was determined in
an ICS-1100 (Thermo Fisher, America). The suspension was first centrifuged to form clear water samples,
and then passed through a filter membrane to ensure no
particles left in the sample.
RESULTS AND DISCUSSION
Optimization of Processing Water Treatment in
Bauxite Flotation
Influence of pH Value on Pulp Sedimentation
Figure 2. Cumulative size distribution of bauxite ore, concentrate
pulp and tailing pulp.
Bench-scale Flotation Tests
At pre-test stage, the concentrate pulp was more
difficult to settle than the tailing pulp, as the same
amount of PAM was used as flocculant. The suitable
dosage was developed for concentrate pulp and tailing pulp respectively. The pH value is an important
factor for PAM adsorption in minerals [32]. In order to get the qualified recycling water, the influence
of pH on the sedimentation of concentrate pulp and
tailing pulp were studied under the suitable dosage
of PAM. The results are provided in Figure 3. The
sedimentation performance was evaluated according
to the supernatant turbidity. It can be seen that the
concentrate pulp shows the best sedimentation performance in neutral pH solution. The tailing pulp exhibited the best sedimentation in the pH range of 6 to 7.
When the pH value is higher than 7, the supernatant
turbidity increases with pH, which indicates reduced
sedimentation performance.
The flotation tests were carried out in a 750 ml flotation cell using one roughing-one scavenging-one
cleaning flowsheet. The pulp was made by adding
320 g minerals into the flotation cell, followed by adding deionized water to the cell volume and subsequent
mixing procedure. In the roughing process, the pH value of the pulp was adjusted to 10 using sodium carbonate, and then 60 g/t sodium hexametaphosphate was
added as dispersant. Conditioning time for adjusting
the pH value and the dispersant were 6 and 5 minutes,
respectively. The collector was added two times, and
the dosage was 400 g/t and 300 g/t, with the conditioning time of 4 and 3minutes, respectively. Cleaning process was carried out without reagents addition, while
300 g/t collector was added in the scavenging process.
During the tests, the impeller speed was 1600 r/min,
and the temperature was 25°C ± 2°C.
Figure 3. Influence of pH on sedimentation of concentrate pulp and
tailing pulp (Cconcentrate = 80 g/t, Ctailing = 40 g/t).
Methods
Settlement Tests
The settlement tests were carried out in a 500 ml
cylinder with a stopper. The concentration of the slurry
used in the tests was 5% (g/ml). The PAC was added
first to the slurry, followed by turning the cylinder upside down three times to mix uniformly. Next, PAM
was added followed by the same mixing procedure.
The supernatant height was collected during the tests.
After settlement, the supernatant was collected, and
the turbidity was measured with a 2100 N turbidimeter
(HACH, America).
166
L. SUN, Z. MA, L. LIAN, Q. WANG, L. SUN and J. LIU
Effect of Combination Agent on Sedimentation
With the addition of PAC into the wastewater, the
time for floc formation can be reduced, and the characteristics of the flocs were enhanced [33]. Therefore,
PAC was used coordinated with PAM in the study, and
the effect of combination agent on the sedimentation
of concentrate pulp and tailing pulp were studied. The
sedimentation performance is evaluated according to
the settling rate and the supernatant turbidity (See Figure 4). As PAC is used alone, the settling rate is the
minimum one for both concentrate pulp and tailing
pulp, compared to the case when PAC is used coordinated with PAM. Meanwhile, the supernatant turbidity
decreases over the concentration of PAC. When PAC
is used coordinated with fixed dosage of PAM, the settling rate almost decreases with the increasing of PAC
concentration. For the tailing pulp, the supernatant tur-
bidity decreases with PAC concentration. For the concentrate pulp, as PAC is used alone, the supernatant
turbidity decreases with PAC concentration. However,
there is no obvious regularity when the PAC is used
with PAM.
Generally, particles tend to coagulate and aggregate
through the electrostatic patch effect, charge neutralization, bridge connection, and sweep flocculation in
series or synchronously [34]. In reference 35, the diameter of the particles studied was 3 μm, and the coagulation region can be divided into two parts, negative
zone (part I) and positive zone (part II) according to
the zeta potential (See Figure 5 ). The main mechanism
was ascertained to be the charge-neutralization in part I
and sweep flocculation in part II. Thus, the coagulation
behavior of the concentrate pulp in this work agrees
well with the reference, since the particle diameter is
similar.
Figure 4. Effect of combination agent on supernatant turbidity and settling rate of concentrate pulp and tailing pulp.
Optimization of Processing Water Treatment and Its Reuse in Bauxite Flotation
167
Figure 5. Zeta potential and residual turbidity as a function of coagulant dosage: (a) zeta potential and (b) residual turbidity ([Al]T equals to the
total aluminum concentration added in) [35].
Reuse of Processing Water in Bauxite Flotation
Processing Water Reused Twice in Bauxite Flotation
Processing Water with Different Turbidity Reused in
Bauxite Flotation
The pulp was pre-treated as mentioned above, and
the supernatant with 100 NTU was used with recycling
water, which was referred to as the first cycle. Subsequently, the pulp of concentrate, middling, and tailing
were treated by sedimentation process. All of the pulps
were settled around pH 7, and then PAC along with
PAM were added into the concentrate pulp and tailing
pulp as described above, while the middling pulp were
treated as tailing pulp. The supernatant was then mixed
and used for flotation, which was referred to as the second cycle. The flowsheet of recycling water used in
flotation was shown in Figure 6.
After reusing the recycling water twice, the flotation
results are shown in Table 2. As the recycling water is
reused in the first cycle, the concentrate with A/S ratio
of 6.4 is measured, and the recovery of Al2O3 reached
72%, which was higher than using fresh water. However, when the recycling water was settled for the sec-
In order to determine if the processing water treated
by the sedimentation process was suitable for the flotation test, the water was reused in flotation, and the
results are listed in Table 1.As can be seen from the
table, when the turbidity of the water is 1908 NTU and
95 NTU, the final A/S ratio is less than 6, which cannot
meet the demand of the bauxite production. Comparing
the results from sample No.1 to No.4, we can conclude
that the A/S ratio of the concentrate increases with the
decreasing of water turbidity. This is mainly because
that the high turbidity is induced by ultrafine particles
such as kaolinite and illite, which are hard to settle.
When the processing water with high turbidity is reused in flotation, the ultrafine particles can be floated
to concentrate through coating and foam entrainment,
which lowers the concentrate grade.
Table 1. Flotation Results of Bauxite using Recycle
Water with Different Turbidity.
Number
No.1
No.2
No.3
No.4
Concentrate (%)
Turbidity of
Recycle Water
(NTU)
Recovery
(%)
Al2O3
(%)
SiO2
(%)
A/S
1908
95
57
0
61
67
72
49
61
62
62
66
13
12
10
10
4.7
5.2
6.2
6.6
Figure 6. Flowsheet of recycling water used in flotation.
168
L. SUN, Z. MA, L. LIAN, Q. WANG, L. SUN and J. LIU
Figure 7. Concentration of Cl– in recycled water.
ond time and reused in flotation, the recovery of Al2O3
increases to 86%, and the A/S ratio of the concentrate
decreases to 4.9, which indicates reduced selectivity in
bauxite flotation.
In bauxite, diaspore is the main mineral, and kaolinite is the typical clay mineral. During the sedimentation process, the PAC coagulates the ultrafine particles
through compressing the double electrode layer on the
clay surface. It is generally recognized that effective
particle aggregation is caused by the positively charged
aluminum of PAC [37,38], so the chloride ions accumulate in the process water. The concentration of the
chloride ions in the recycle water is shown in Figure 7.
Inorganic electrolytes such as NaCl are favorable
to form smaller stable bubbles [36], and the smaller
bubbles can enhance the flotation performance through
increasing particle-bubble collision probability [37].
Thus, increasing ionic strength can result in increased
gangue entrainment [38,39].
CONCLUSIONS
The sedimentation of bauxite concentrate pulp and
tailing pulp were investigated. The results show that
neutral pH is beneficial to the sedimentation of concentrate pulp and tailing pulp. Optimization of PACPAM dosage can achieve supernatant with turbidity
about 100 NTU. Based on the sedimentation results,
the flotation tests were carried out to study the effect of
water tuebidity and recycle time on the A/S ratio and
recovery of the concentrate. Results show that the A/S
ratio increases with the decreasing of water turbidity.
When the process water treated based on the optimum
sedimentation condition is reused in bauxite flotation
for two cycles, the A/S ratio are 6.3 and 4.9, respectively. By measuring the ion content of the water, chloride
ions are found to accumulate in the processing water,
which may increase gangue entrainment in bauxite flotation.
ACKNOLEDGEMENTS
Table 2. Flotation Results of Bauxite that Reused
Recycling Water Twice.
Product
Recovery
(%)
Al2O3
(%)
SiO2
(%)
A/S
First
Concentrate
Middling
Tailing
72
22
6
70
51
30
11
20
25
6.4
2.6
1.2
Second
Concentrate
Middling
Tailing
86
6
7
64
51
37
13
21
29
4.9
2.4
1.3
Cycle
This work was financed by the the National Science
& Technology Pillar Program during the 12th Fiveyear Plan Period (2014BAB01B05) and Natural Science Foundation of Jiangsu Province (BK20150192).
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